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Hazard prediction worksheet
A hazard prediction worksheet is a short team talk, on paper, before a non-routine or maintenance job: the team lists the steps, says what could go wrong at each one, scores it, and agrees what to change before starting. This worksheet scores each step on three numbers: the severity of the worst realistic outcome from 1 to 5, the likelihood from 1 to 5, and the strength of the control in place, with an engineered control worth 1, a rule or procedure worth 2 and nothing but care worth 3. The three add up to a score from 3 to 13 in three bands: low, medium and high. A high step means stop and change the plan or the equipment first. After the countermeasure, the team scores the step again to see what it bought. The PDF has four landscape pages: the worksheet, a team agreement with the one thing the team will watch today and a sign-in, the scales, and a worked example of a motor swap on a conveyor at height. The Excel version works out the score and band, says whether the job can start, flags a step that still needs a countermeasure, and keeps a log of jobs and scores over time. It is quicker than a full job safety analysis and meant for the jobs that do not have one.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Fields for job, date, place and team leader above a table with columns for each step, what could go wrong, severity, likelihood, control and score, a countermeasure, and the re-score.Step-by-step worksheetSeverity, likelihood and control scoresRe-score after the countermeasureTeam agreement and sign-inScales and bandsJob logWorked example
When to use it
When to use a hazard prediction worksheet
- Before a maintenance job, a changeover, a repair or any other non-routine task that has no written procedure with its hazards.
- At the pre-job talk, so that the team scores the steps together and agrees one thing to watch.
- When something changes on a routine job: new people, new parts, a different place or different weather.
- To give a team leader a quick way to test whether a planned step is safe enough, and to show what a countermeasure achieved.
- Not as a substitute for a job safety analysis of a routine task (use that for repeated work) or for a permit where one is required.
How to fill it in
- 1
List the steps of the job
Write the steps in order, at the level of what the hands do: set up the platform, lower the old motor, lift the new one. Four to ten steps is typical.
- 2
Say what could go wrong at each step
For each step, write the thing that could hurt someone: a load drops, a hand is caught, a conveyor restarts. Ask the people who do the job what they have seen.
- 3
Score severity, likelihood and control
Score the worst realistic outcome from 1 to 5, the chance it happens today from 1 to 5, and the control in place: engineered 1, rule or procedure 2, nothing 3. Add the three for the score.
- 4
Act on the high and medium steps
A high step (10 or more) means stop and change the plan or the equipment before doing it. A medium step (7 to 9) needs a countermeasure agreed before the step and someone to check it.
- 5
Score again with the countermeasure
Write the new severity, likelihood and control. The drop in the score shows what the countermeasure bought. If the score is not lower, the countermeasure is not good enough.
- 6
Agree the one thing to watch and sign in
Pick the step that scored highest or worries the team most and write it as a sentence everyone can repeat. Everyone signs in, and anyone can stop the job.
A filled-in example
Illustrative, not a benchmarkAn example: a team of three swaps a conveyor drive motor at height. The steps, scores and countermeasures are invented.
- Before the job, two of the eight steps were high: lowering the old motor scored 10 and lifting the new motor onto the bracket scored 11. Six were medium.
- The lift scored 11 because the severity was 4 (a dropped motor could cause a severe injury), the likelihood was 4 (it would probably happen today with hand lifting) and there was no control (3).
- The countermeasure was a hoist and a second person to guide the load. Re-scored, the load is held so the severity is 3, the second person makes it very unlikely so the likelihood is 1, and the hoist is an engineered control worth 1. The step scores 5.
- After all the countermeasures nothing is high, two steps are medium and six are low. The team agreed to watch one thing: nobody stands under the motor while it is lifted.
The scores came down because the controls changed from care to equipment. The job log shows the same team's highest score fall from 11 to 7 on this job. The numbers are invented to show how the worksheet is used.
Common mistakes
Doing it alone at a desk
The people doing the job know what has gone wrong before. Score it together at the job, with the team, before the first step.
Scoring the countermeasure as a rule
A new rule is an administrative control, worth 2 at best. If the re-score hardly drops, look for a physical control: a hoist, a guard, a lock, a barrier.
Writing steps too big to score
Do the repair is not a step. Break the job into the actions where a person could be hurt, so each can be scored and controlled.
Not stopping on a high score
A high score is the point of the worksheet. If the team carries on anyway, the exercise is paperwork. Change the plan, or change the equipment.
Forgetting to score again
Without the second score you do not know whether the countermeasure worked. Write it for every medium and high step.
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FAQ
Hazard prediction worksheet: common questions
Hazard prediction is a short team exercise before a job in which the team lists the steps, says what could go wrong at each, scores the risk and agrees countermeasures before starting. It brings the hazards into the open at the point of work.
A job hazard analysis is a fuller written study of a task, often kept as a procedure for repeated work. A hazard prediction worksheet is a quick pre-task talk for a specific job, scored before and after, and is meant for non-routine and maintenance jobs that have no written analysis.
Add the severity of the worst realistic outcome (1 to 5), the likelihood (1 to 5) and the control points (engineered 1, administrative 2, none 3). The total from 3 to 13 gives low, medium or high. The scales and bands are an example you can change.
Stop and change the plan or the equipment before doing the step. Look first for a physical control such as a hoist, a guard or a lock, because a rule alone rarely lowers the score much. Then score again.
Yes. Signing in shows that everyone has seen the scores and the one thing to watch, and that anyone can stop the job if something changes.
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- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Loss tree worksheetBreak one big loss number into area, line, machine, loss type and cause, and stop at the cause a team can fix.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Compressed air leak survey logWalk sheet, printable leak tags and a tracker that puts an annual cost on every leak and follows it to a verified fix.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Project savings validation checklistThe gate between a project's claim and a reported saving: 20 checks, a claims register and a six-month sustainment check.
- Life cycle cost analysis templateCompare up to three machines over ten years: price, energy, upkeep, failures and down time, discounted to present value.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Energy loss matrix templateSeven types of energy loss by six energy sources with a cost in each cell, an action plan and an idle-period shutdown checklist.
- Environmental compliance audit checklistAn internal environmental audit: 37 questions with what to look for, a findings log with classes and a score by section.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.